Embossed nonwoven wiping and cleaning materials

ABSTRACT

An embossed nonwoven fabric having a textured character and fabriclike qualities of softness and hand and suitable for wiping surfaces having aqueous and/or oleaginous liquids and/or more viscous semisolids thereon comprising a web containing at least one layer of overlapping, intersecting fibers, a pattern of intermittantly spaced, embossed, compacted or densified fibrous areas lying in the planes of both surfaces of said web of overlapping, intersection fibers, and a pattern of unembossed, uncompacted fibrous portions lying between said planes and connecting said embossed, compacted fibrous areas.

llnited States Patent Inventor .1. Harold Smith Amherst, Mlass. 848,502

Appl. No. Filed Patented Assignee Aug. 0, 1969 Oct. 26, 1971 Johnson 8:Johnson EMBOSSED NONWOVEN WlllPllNG AND CLEANIING MATERHALS 15 Claims,18 Drawing Figs.

U.S.C1 161/124, 15/209, 161/146, 264/286 llnt. C1 A471 25/00, B32b 3/00Field of Search 161/124,

[56] References Cited UNITED STATES PATENTS 3,017,304 1/1962 Burgeni161/123 3,047,454 7/1962 Marcalus 162/117 3,301,746 1/1967 Sanford et al162/113 Primary Examiner-William A. Powell Attorneys-Alexander T. Kardosand Robert L. Minier PATENYEBUM 26 us?! SHEET 30F 6 INVENTOR f ///l ?0L0S/wn ATTORNEY PATENTEDnm 2s IBYI SHEET 5 BF 6 all.

} T1E JE.

4am FA ATTORNEY EMBOSSED NGNWOVIEN WIIPING iiiltlllll CLEANING MATERIALSThis invention relates to nonwoven fabrics and more particularly toembossed nonwoven fabrics having improved wiping rates or cleaningefficiencies and well suited as wiping or cleaning materials forsurfaces having aqueous and/or oleaginous liquids and/or more viscoussemisolids thereon.

In the past, nonwoven fabrics comprising at least one layer ofoverlapping, intersecting fibers have been used as wiping and cleaningmaterials for aqueous and/or oleaginous liquids and/or more viscoussemisolids, such as water, syrups, aqueous solutions, chemicals, oils,fats, waxes, greases, cosmetics, etc. and have met with considerablecommercial success. However, it is always desirable to improve theproperties and characteristics of existing commercial products and, inthe case of wiping and cleaning materials, to enhance their wiping ratesand cleaning efficiencies.

Typical examples of nonwoven fabrics which are suitable for wiping,cleaning, and related purposes are noted in US. Pat. Nos. 2,039,312,2,676,364, 2,705,688, 2,862,251, and 2,384,703. It is a primary purposeof the present invention to improve the wiping rates and cleaningproperties and characteristics of such nonwoven fabrics and likematerials.

It has been discovered that such a purpose may be achieved by embossingor compacting the layer or layers of overlapping, intersecting fiberswhich form the nonwoven fabrics or the like in such a way that theembossed or compacted areas lie in the planes of both top and bottomsurfaces of such nonwoven fabrics and therefore directly contact theliquids or scmisolids to be wiped or cleaned. Such has been found toimprove the fluid absorbency and retentivity of the nonwoven fabric andto enhance its wiping and cleaning efficiency. Also, and perhaps moreimportantly, the wetting rate is enhanced due to the compacted structureof the embossed areas which provide capillarity, coupled with avenues ofrapid liquid flow into the body of the nonwoven fabric.

It has further been discovered that a textured character and fabriclikequalities of softness and hand as well as loft, resiliency, and drapemay be retained in the embossed, compacted nonwoven fabrics if theembossing or compacting takes place intermittently in spaced, discreteareas on both surfaces of the nonwoven fabric and wherein unembossed oruncompacted portions having high loft and bulk lie between the planes ofthe surfaces of the nonwoven fabrics and connect the embossed, compactedareas.

The embossed area must not cover the entire surface of each side of thenonwoven fabric. Such overall embossing or compacting will yield astiff, boardy wiping fabric which is entirely undesirably andunsatisfactory. The embossed, compacted areas must therefore beinterrupted by other areas which are not embossed or compacted, or byvoids or gaps in the planar surface of the nonwoven fabric. In the eventthat the compacted areas join one another to form an open networlt orinterconnected grid, such is to be considered as spaced or interruptedembossed areas, provided they meet the other requirements set forth inthis specification.

To more clearly define the nature of the present invention, reference ismade to the following specification and accompanying drawings whereinthere are described and illustrated preferred embodiments of theinvention. This is intended primarily to disclose the invention morefully but not to limit it. With reference to the accompanying drawings:

FIG. I is an idealized, fragmentary cross-sectional view of embossingplates or embossing rolls such as were used in the prior art forembossing nonwoven fabrics;

FIG. 2 is an idealized, fragmentary cross-sectional view of an embossednonwoven fabric of the prior art resulting from the use of the embossingplates or embossing rolls of FIG. ll;

FIG. 3 is an idealized, fragmentary cross-sectional view of the improvedembossing plates or embossing rolls, taken on the line 33 of FIGS. 5 and6, as are used in applying the principles of the present invention;

FIG. d is an idealized, fragmentary cross-sectional view of an embossednonwoven fabric, taken on the line 4-4 of FIG.

7, resulting from the use of the embossing plates or embossing rollsofFIG. 33;

FIG. 5 is an idealized, fragmentary perspective view of a portion ofparts of a pair of mating embossing plates used to make the improvedembossed nonwoven fabrics of the present invention;

FIG. 6 is an idealized, fragmentary plan view of the mating embossingplates of FIG. 5, disclosing the spatial relationship of the embossinglands of both embossing plates;

FIG. 7 is an idealized, fragmentary perspective view of a portion of animproved embossed nonwoven fabric of the present invention resultingfrom the use of the embossing plates of FIGS. 5 and 6;

FIG. 8 is an idealized, fragmentary plan view of a modified form ofmating embossing plates having circular embossing lands of use in theapplication of the principles of the present invention.

FIG. '9 is an idealized, fragmentary cross-sectional view of a modifiedform of mating embossing plates, taken on the line 99 of FIG. 12,showing embossing lands of different size and having differentcompacting forces of use in the application of the principles of thepresent invention;

FIG. 10 is an idealized, fragmentary plan view of a modified form ofmating embossing plates having a diamond-embossing grid anddiamond-shaped embossing lands of use in the application of the presentinvention;

FIG. llll is an idealized, fragmentary schematic view in elevationshowing the use of rotatable embossing rolls of use in the applicationof the principles of the present invention;

FIG. 12 is an idealized, fragmentary plan view of the mating embossingplates of Fig. S, disclosing the spatial relationship of the embossinglands of the mating embossing plates;

FIG. 13 is an idealized, fragmentary plan view of a variation of themating embossing plates of FIGS. 9 and IE but disclosing a variation inthe sizes of the embossing lands of the mating embossing plates;

FIG. 14 is an idealized, fragmentary plan view of a variation of thematingembossing plates of FIGS. 9 and 112 but disclosing anothervariation in the sizes of the embossing lands of the mating embossingplates;

FIG. 15 is an idealized, fragmentary plan view of a modified form ofmating embossing plates having diamond-shaped em bossing lands on onesurface and a grid plate formed with circular holes as the embossingland of the cooperating embossing surface;

FIG. lib is an idealized, exploded, fragmentary cross-sectional viewtaken on line l6ll6 of FIG. 15 showing the mating embossing plates andthe embossed wiping cloth resulting from the operation of such matingembossing plates;

FIG. I7 is an idealized, fragmentary perspective view of a modificationof the pair of mating embossing lands such as illustrated in FIG. 5 butdisclosing an additional technique for forming embossed compactedchannels between the embossed areas in one surface of the nonwovenfabric and the embossed areas in the other surface of the nonwovenfabric; and

FIG. I3 is a further modification of the channel-forming techniques ofFIG. 117 but showing embossed compacted fibrous channels at all fourcomers of the embossed areas of the embossed nonwoven fabric.

Embossed nonwoven fabrics for various purposes are well known in thetextile and related industries, as noted in US. Pat. No. 2,834,703 andparticular reference is made to FIG. 3 of this patent showing a specificembossed nonwoven fabric for cosmetic and related purposes. In themethods disclosed in this prior art patent, embossing plates orembossing rolls having mating surfaces or lands such as illustrated incross section in FIG. ll of this specification are used and an idealizedcross section of the resulting embossed nonwoven fabric is illustratedin FIG. 2 of this specification.

It is to be appreciated that, when the embossed, nonwoven fabric of FIG.2 of this specification is used for wiping or cleaning purposes, theunembossed, uncompacted areas which extend beyond the plane of theunwoven fabric come into more intimate contact with the surface to bewiped or cleaned than do the embossed, compacted areas which lie in theplane of the nonwoven fabric. This results in a wiping or cleaningaction which has been found acceptable in the prior art but which isimproved by use of the principles of the present invention.

According to the principles of the present invention, the formation andbasic construction of the embossing plates or embossing rolls ismodified whereby a novel, improved embossed nonwoven fabric is obtained.As shown in FIG. 3 of this specification, upper and lower mating,embossing plates and 12 are used wherein the respective embossing landsl4, l6 and 18, are parallel but offset with respect to each other and tothe plane of web 11 of one or more layers of overlapping, intersectingfibers constituting a nonwoven fabric, whereby the compacted areas 22,24 (See FIG. 4) of the resulting embossed nonwoven fabric 26 aresimilarly parallel but offset.

Also, as noted in FIG. 4, fibrous portions 28, 30 extend slantingly andangularly from the intermittently spaced embossed, compacted fibrousareas 22 lying in one surface of the nonwoven fabric 26 to theintermittently spaced, embossed, compacted fibrous areas 24 lying in theother surface of the nonwoven fabric 26. These fibrous portions 28, 30are unembossed and uncompacted and retain their original softness, bulk,and loft and provide fabriclike qualities of softness and hand, as wellas loft, resiliency and drape to the embossed nonwoven fabric 26.

The compacted areas 22 and 24 thus form a pattern of intermittentlyspaced, separate and discrete, embossed, compacted fibrous areas whichlie in the planes of the substantially parallel top and bottom surfacesof the nonwoven fabric, whereas the unembossed, uncompacted portions 28,30 lie between these planes and hingedly connect the embossed, compactedareas. With such a configuration, it is to be appreciated that, when theembossed, nonwoven fabric 26 of FIG. 4 is used for wiping or cleaningpurposes, an entirely new principle and cleaning action is involvedwherein the compacted areas 22, 24 come into more intimate contact withthe surface to be wiped or cleaned than do the uncompacted areas 28, 30.As will be pointed out hereinafter, such principles result in anenhancement of the wiping and cleaning efficiency.

It is to be pointed out, moreover, that the compacted areas have superbliquid-wiping efficiency and act in the fashion of wiping blades orbarriers which snowplow" liquids, greases, and semisolids. Also, thepockets or voids 29 (See FIG. 4) in the structure of the nonwoven fabrichold the grease or other materials being wiped out of direct pressingcontact with the surface being wiped.

In FIG. 5, there is illustrated one form of the lower embossing plate 12capable of making one typical embodiment of the embossed nonwoven fabricof the present invention. The embossing surfaces or lands 16 of thelower embossing plate 12 are squares and are arranged in substantiallyparallelspaced checkerboard rows. The upper embossing plates 10 whichpossesses substantially parallel-spaced checkerboard rows of embossingsurfaces or lands 18 is shown fragmentarily, in order to avoid confusingFIG. 5, but its action and mating embossing function with the lowerembossing plate 12 is obvious.

FIG. 6 discloses a plan view of the spatial relationship of theembossing lands 16 and 18 of the lower and upper embossing plates 12 and10, respectively. The intermittent spacing and arrangement of theselands in such that one pair of lands (14, 16, for example) forces thenonwoven fabric in one direction to be compacted in one surface of thenonwoven fabric whereas an adjacent pair of lands (18, 20 for example)forces the nonwoven fabric in the other direction to be compacted in theother surface of the nonwoven fabric.

The resulting three-dimensional, embossed effect is well illustrated inFIG. 7. It is to be appreciated, however, that such an effect is theresult of having embossing lands with mating square cross sections. Suchspecific cross sections are merely illustrative of the presentinvention. Other geometric shapes and figures may, of course, by used,and include, for example, polygons, including triangles, rectangles,diamonds, pentagons, hexagons, octagons; curved figures such as circles,ellipses, ovals, etc., or combinations thereof. Irregular figures anddesigns may also be used such as hearts, stars, or even symbols orinsignia such as fluer-de-lis, crowns, coronets, etc.

Patterns in the forms of grids or interconnected lines which may becontinuous or discontinuous, narrow or broad, straight or wavy, may beused. Their general direction or orientation may be in the machine orlong direction, parallel to the predominant fiber orientation, if a cardweb is used, or they may be in the cross or short direction,perpendicular to the predominant fiber orientation, or they may bediagonally or angularly positioned, as desired or required.

FIG. 8 discloses the spatial arrangement of circular geometric figures32, 34 as the mating embossing lands; other arrangements and the use ofother shapes or figures are also of use. These are not shown in thedrawings as their arrangement and use is believed clear.

It is not essential that the same geometric shape or figure be used oneach side of the nonwoven fabric. Nor is it essential that the sameamount of surface coverage of compacted area be present on each side ofthe nonwoven fabric. For example, FIG. 9 discloses a cross section ofmating, embossing plates 36 and 38 wherein large rectangular embossed,compacted areas 40 are formed on one surface of the nonwoven fabric 41and small rectangular embossed, compacted areas 42 are formed on theother surface of the nonwoven fabric 41. Unembossed or uncompactedfibrous portions 44 and 46 are noted as lying between the top and bottomsurfaces of the nonwoven fabric and angularly and slantingly join thecompacted areas 40, 42 in a hinged relationship.

The relative size and relationship of the embossing lands of the mating,embossing plates 36 and 38 is more clearly illustrated in FIG. 12 andreference thereto will indicate that the small embossed areas 42 areformed by the small lands 116 which are approximately one-quarter thedimensions of the large lands 118 which form the large embossed areas40. As a result, the total area of the small embossed area 42 is onlyonesixteenth of the total area of the large embossed area 40.

The relative size and spatial relationship of the lands of thecooperating mating, embossing plates or lands may be varied widelydepending on the needs or requirements of the particular situation. Forexample, in FIG. 13, there is illustrated a pair of embossing lands 216and 218 which vary in relative size to a greater degree than theprevious pairs of lands shown in FIG. 12.

In FIG. 14, the variation in size of the pair of lands 316 and 318 isincreased to even a greater degree. Also, it is to be noted that theshapes of the lands have been varied from the previous square-squarerelationship to a square-rectangular,

relationship.

FIG. 10 discloses a simplified plan view of mating embossing plateswhereby diamond-shaped compacted areas are capable of being formed onone surface of the nonwoven fabric by means of diamond-shaped lands 050and a relatively thin diamond grid of compacted lines is capable ofbeing formed in the other surface of the nonwoven fabric by acorresponding relatively thin diamond-grid land 52. This, of course,results in different patterns on each surface of the resulting nonwovenfabric.

The diamond-shaped lands 50 are, of course, integral with one member ofa pair of cooperating mating embossing plates and the daimond-grid land52 is, of course, integral with the other member of the pair ofcooperating mating embossing plates.

The majority of these geometric figures can be produced by machine shopmilling procedures. However, in the event that such procedures aredifficult or uneconomical to carry out for a particular shape or figure,then other known techniques are readily available in the art. Such othertechniques include engraving, etching, electrodeposition, perforatedplate sleeves, etc.

Regardless of the shape, form or number of geometric figures which areinvolved, it is essential that there be a pattern of intermittentlyspaced, separate, discrete embossed compacted areas in at least oneplane of the surfaces of the nonwoven fabric. Such a configuration willinsure the positioning of the compacted densified areas where desiredand will also insure that the unembossed, uncompacted portions do notlie in the planes of the surfaces of the nonwoven fabrics or extendbeyond such planes but lie between these planes and do not directlycontact the surfaces to be cleaned. FIGS. and l6 illustrate the use of arather unusual pair of cooperating, mating, embossing plates 90 and 92.Plate 90 is formed from a platelike member 91 from which a plurality ofcircular holes 94 have been removed, for example, by drilling. The holesare aligned in parallel rows which nest or fit together in a staggeredrelationship as seen in FIG. 15. It is to be appreciated that thesurface or area 104 around the circular holes 94 actually forms theembossing lands of plate 90. The apertured platelike member 91 isrelatively thin and is secured to a base 93 and the two elements formone member of the pair of cooperating mating embossing plates 90 and 92.

The other member of the pair of cooperating mating embossing plates isthe plate 92 which possesses a plurality of diamond-shaped lands 96which are so positioned that they are aligned with the circular holes 94and can be moved reciprocatingly within the space created by thesecircular holes.

Consideration of FIG. 16 will reveal that diamond-shaped lands 96 willcooperate with the opposed surfaces 98 of baseplate 93 to form anembossed compacted fibrous area 100 in the nonwoven fabric 102. Also, atthe same time, the upper surface 104 of the embossing plate 90 willcooperate with the opposed surface 106 of the mating embossing plates 92to form embossed compacted fibrous areas 108 of the nonwoven fabric 102.Again, it is to be noted that a pattern of unembossed, uncompactedfibrous portions 110 and 112 are formed and that they are within theplane of the embossed nonwoven fabric and hingedly and slantinglyconnect the embossed areas 100 and 108 in the same way as describedpreviously.

The result of such application of the principles of the presentinvention will yield a two-faced fabric. One side will have a series ofintermittently spaced, discrete diamondshaped embossed areas, whereasthe other side will have a compacted area corresponding to that of thesurface of plate 91.

Embossing plates which reciprocate rectilinearly in their embossingaction have been found to be capable of satisfactory use and have manyadvantages. However, the use of rotatable embossing rolls is desirablein many instances, particularly where large scale manufacturingproduction is involved.

In FIG. ill, there is illustrated a typical arrangement involving theuse of rotatable mating embossing rolls 60, 62. Projections or embossinglands 64, 66 extend from the surfaces of the rolls 60, 62, respectively,somewhat generally resembling gear teeth, and cooperate with thesurfaces 68, 70, respectively, of the opposed rolls 62, 60. in this way,a plurality of webs of overlapping, intersecting fibers constituting asubstantially flat nonwoven fabric 72 is introduced between theembossing lands and opposed surfaces and is embossed in an offset manneras described herein. This yields compacted areas 74, 76 which lie in theplanes of the surfaces of the nonwoven fabric 72 and are connectedhingedly and angularly by unembossed and uncornpacted portions '78, 80.The compacted areas are intermittently spaced not only radially by theembossing rolls which is equivalent to a lengthwise direction of thenonwoven fabric but they may also be intermittently spaced axially byremoving portions of the projections 64, 66 at regularly spaced locationin an axial direction. This intermittcntly spaces the compacted areas ina widthwise direction of the nonwoven fabric. Squares, diamonds, andrectangles would be the most common form of embossing lands em ployed onsuch rotatable rolls, although any geometric shape or figure ispossible.

In the embodiments of the invention described and illustrated thus far,the compacted fibrous areas in one plane of the nonwoven fabric areseparate and distinct from the compacted fibrous areas in the otherplane of the nonwoven fabric. This is usually desirably but in somecases it may be desired to connect them with relatively narrow, fibrouschannellike members which are also embossed or compacted whereby fluidflow therealong is expedited.

One method of accomplishing this is illustrated in FIG. 17 wherein theprinciple is illustrated in the formation of merely one channelliltemember. In this Figure, the nonwoven fabric being embossed is omittedfor purposes of clarity. A pair of adjacent embossing lands 416 and 418are shown and it is to be appreciated that upward relative movement ofland 4116 will form a compacted or embossed fibrous area on its uppersurface. At the same time, downward relative movement of land 4116 willform a compacted or embossed fibrous area on its lower surface. Such hasbeen described previously. These compacted areas would normally not beconnected. However, a pair of channel-forming lands 420 and 422 areformed adjacent to and integral with the lands M6 and dill,respectively, and have sloping surfaces 424 and 426 which oppose eachand come together to emboss or compact a slanting channellilte fibrouscompacted strip which extends angularly between the embossed areas inthe surface of the nonwoven fabric.

FIG. 118 discloses the application of such channel-forming techniques toa nonwoven fabric 430. Four square-shaped compacted areas 432 are shownwhich exist in one plane of one surface of the nonwoven fabric 430. Onesquare-shaped compacted area 434 is shown which exists in the otherplane of the other surface of the nonwoven fabric 430. Four channellikemembers 436, 439, 440 and 442. are shown connecting all these compactedareas, whereby fluid flow between these areas is facilitated andexpedited.

The degree of compaction or the amount to which the fibrous areas can bedensified is controlled and regulated by the clearance between theembossing lands and the opposed embossing surfaces. A moderatecompaction yields excellent wiping and capillarity along with goodresilience, softness and hand. Heavier compaction facilitates bondingcharacteristics where such properties are of interest, particularly ifany potentially softenable and fusible thermoplastic fibers or materialsare used. Reference to FIG. 9 will reveal that the degree of compactionneed not necessarily be the same on both sides of the nonwoven fabricbut may be different. The degree of compaction is controlled andregulated by changing the clearances between the embossing lands andthe: cooperating opposed embossing surfaces.

In FIG. 9, the embossing lands and cooperating opposed embossingsurfaces are closer together in the formation of the small embossed area42 than are the embossing lands and cooperating opposed embossingsurfaces which form the large embossed area 40. As a result, theembossed area 42 is much more compacted and bonded together than theembossed area 40.

The compression forces required to obtain the degree of compactionrequired will vary widely within the principles of the presentinvention. Compression forces of from about pounds per square inch toabout 10,000 pounds per square inch have been found satisfactory.However, from about 100 to about 1,000 pounds per square inch ispreferred as such avoids the destructive effects of crushing and cuttingoccasionally noted at very high pressures for some patterns. The timeintervals for the application of such compressive forces will also varywidely and, within the principles of the present invention, good resultsare obtainable using application times of approximately onetwo-hundredth of a second to about one onehundredth of a second or more.Such a time interval is also classifiable as substantiallyinstantaneous. If it is desired to apply the compressive forces atelevated temperatures,

such may be done at temperatures of from about 212 F. to about 450 F.,with preferable limits being from about 250 F. to about 350 F.

Normally, the natural moisture regain of the cellulosic fibers issufficient in order to obtain satisfactory results. Such naturalmoisture regain is normally in the area of from about 6 percent to about10 percent. On occasion, if it is desired, additional moisture may beapplied to bring the moisture content up to 30 percent or 60 percent, oreven more, where additional moisture and compaction is desired.

The amount of surface coverage of the compacted areas in the planes ofthe surfaces of the nonwoven fabric may vary widely, and as pointed outherein with particular reference to FIG. 9 and 10, need not be equal.Within the broader aspects of the present invention, however, thesurface coverage of the compacted area on each side of the nonwovenfabric may be as low as a fraction of 1 percent and as high as about 90percent. Within the narrower and more preferred aspects, however, thesurface coverage of the compacted areas on each side of the nonwovenfabric is in the range of from about 10 percent to about 40 percent.

By a judicious selection of the shape of the geometric pattern for eachside of the nonwoven fabric and by varying the amount of surfacecoverage for each side, different properties and characteristics can becreated in each side whereby a twosided product is obtained with adifferent function or use for each side.

The nonwoven fabrics of the present invention normally comprise fibrousmaterials of a cellulosic origin inasmuch as the fluid absorbency andretentivity of such fibrous materials is best suited for the purpose ofthe present invention. Cotton fibers, rayon, cotton linters, wood pulp,and the like are exemplary of such cellulosic materials. When the fiberlength of such materials is very short, as in the case of cotton lintersor woodpulp fibers, and create difficulties in handling and processing,they are preferably either mixed in varying proportions with fibers ofgreater length and thus handled and processed, or they may form thecentral layer of a three layer sandwich in which the two outer layerscomprise longer fibers.

Other fibers, such as polyolefinic, polyester, nylon 6 or 66, acrylics,modacrylics, fluorocarbon, spandex, acetate, etc. or other naturalfibers such as wool, silk, etc., may be used in varying percentages,from about 5 percent by weight up to about 25 percent by weight, or evenmore, where special properties or characteristics are desired in thefinal product. The thermoplastic fibers noted above are of useparticularly if some degree of softening and thermoplastic fusion isdesired.

The nonwoven fabrics of the present invention comprise one or morelayers of overlapping, intersecting fibers and are preferably derivedfrom card webs wherein the individual fibers are relatively moreoriented in the long or machine direction. However, they may also beprepared by various airlaying techniques or similar processes wherebythe nonwoven fabric is relatively more isotropic.

The nonwoven fabrics may be processed according to the principles of thepresent invention in an unbonded state, or, if desired, they may belightly bonded by any of the many known bonding agents common in thenonwoven industry and then embossed in such lightly bonded condition.

The embossing and compacting may take place with the nonwoven fabrics inrelatively dry condition, that is, merely containing the naturalmoisture regain which under normal conditions is about 6l0 percent byweight but in some cases may range up to about 20 percent by weightunder conditions of high humidity and high temperature. If desired, someadditional moisture or steaming up to 60 percent moisture or more may beresorted to in order to obtain a greater set in the embossed compactedareas.

The embossing plates or rolls may be operated at room temperatures or atelevated temperatures, if desired, and temperatures up to 212 F. or evenas high as 450 F. may be employed to accentuate the set of the fibersand to improve their shape retention. Such elevated temperatures mayalso be restored to if thermoplastic fusible fibers are included and itis desired to obtain some degree of fiber softening and fusing thereof.

A light spray of a resin or other coating or impregnant may be appliedby roller or padding techniques to the embossed, compacted nonwovenfabric, after embossing, preferably only on the embossed, compactedareas to enhance the shape-stability of the embossed nonwoven fabric.Too heavy a resin treatment, particularly on the unembossed, uncompactedportions, would be undesirable for many purposes, particularly whensoftness, drape and hand are desired in the final product.

The resin or other coating which is applied to the nonwoven fabric afterembossing need not necessarily be applied to both sides. If desired, itmay be applied only to one side or, if desired, two different resins orcoatings may be applied whereby a two-sided product is obtained. Forexample, a gritty or abrasive binder may be applied to one side and asoft and yielding binder may be applied to the other side whereby ascrubber-wiper nonwoven fabric is obtained.

If desired, the nonwoven fabrics may be strengthened by the inclusiontherein of reinforcing fabrics or other structures, such as, gauze,woven or nonwoven scrim, warp sheets, plastic screening or netting, andthe like. Again, the addition of such materials would depend upon therequirements and needs of the particular situation.

The nonwoven fabrics of the present invention vary widely in weight. Theminimum weight is dictated by the amount of fibers required to form aweb or sheet which can be handled during subsequent processing. As such,web weights may be as low as about 170 grains per square yard butnormally fall in the area of at least about 400 grains per square yard.The upper limit is dictated by the particular fabric requirementsinvolved and normally range up to about l,200 grains per square yard.Heavier weights are, of course, possible, depending upon the particularcircumstances involved.

The invention will be further described ingreater detail by reference tothe following examples wherein there are set forth specific embodimentsof the invention which are intended to illustrate the concepts involvedbut not to limit the same.

In the following Examples, reference will be made to wiping rates ofvarious fabrics. These are the results of comparative tests and areobtained as follows: a rotatable turntable having a diameter of 20 feetand somewhat generally resembling a record player turntable is made ofthe surface to be wiped, usually plateglass. A thin film of the aqueousor oleaginous material to be wiped is applied to the surface of theturntable such as by a multiroll applicator to insure even, controlledfilm application. If the film is clear and colorless, a dye may be addedto make it visible. The wiping fabric is then placed on the turntableand a known weight is placed on the fabric to insure a known constantwiping pressure against the turntable. The turntable is then rotated ata constant speed (rpm) and the rapidity of wiping the surface clean orthe wiping rate is determined by direct observation. The results do notrepresent absolute values; they are all relative values but they dorepresent true and reproducible comparisons between different wipingfabrics.

EXAMPLE I A pair of cooperating mating embossing plates as illustratedin FIGS. 5 and 6 is prepared to the following specifications: 5 groovesper inch, cut in two directions at right angles; groove width is 0.125inch; groove depth is 0.0625 inch; land width is 0.075 inch; top andbottom mating embossing plates are identical and mated as shown. Thereare 25 squares per square inch in each plate; each square having an areaof 0.005625 square inch. The surface coverage of each set of lands isl4.l percent. The fabric of FIG. 7 is prepared.

These mating embossing plates are used to emboss an unbondedwoodpulp-filled card web sandwich comprising outer layers of slightlyprebonded KEYBAK rearranged apertured nonwoven rayon card webs eachweighting grains per square yard and a centrally located woodpulp layerweighing 350 grains per square yard, thus making a total weight of 600grains per square yard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that the embossed wiping fabric has a twofoldimproved wiping rate over the unembossed wiping fabric for a water filmon a glass surface. The wiping rate of the embossed wiping fabric issubstantially improved twofold over an unembossed wiping cloth forwiping an oil film on a glass surface.

EXAMPLE ll A pair of cooperating mating embossing plates as illustratedin H65. 115 and 16 is prepared to the following specifications: thecircular holes are drilled in a plate member to five-sixteenths inch(0.3125 inch) diameters and are aligned with one-sixteenth inch (0.0625inch) spacing between adjacent aligned circular holes. Horizontalalignment, from right to left, as noted in FIG. is involved here. As aresult, there are 20 circular holes per 7.50 inches of plate member, or2.67 circular holes per inch in one direction. In the other direction,which is vertical, from top to bottom, as viewed in FIG. 15, due to the60 nesting or staggered relationship of the circular holes, there are 20circular holes per 10.875 inches of plate member, or 2.92 circular holesper inch. As a result, there are a total of 7.8 circular holes persquare inch of plate member. The area of each circular hole is 0.0767square inch. This creates a total area of the circular holes of 0.60square inch per square inch of plate. The embossing area of theperforated drilled plate is therefore 1 square inch less 0.60 squareinch or 40 percent.

With regard to the diamonds, there are also 7.8 diamond lands per squareinch and each diamond has a long diagonal of about 0.30 inch and a shortdiagonal of about 0.173 inch with an apex angle of about 60. The area ofa diamond is therefore 0.0263 square inch and the total embossing areafor 7.8 diamonds per square inch is 0.205 square inch or 20.5 percent.

These mating embossing plates are used to emboss an unbondedwoodpulp-filled card web sandwich comprising outer layers of KEYBAIKrearranged apertured nonwoven rayon card webs each weighing 125 grainsper square yard and a centrally located woodpulp layer weighing 350grains per square yard, thus making a total weight of 600 grains persquare yard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that with regard to usage on the perforateddrilled plate side, the embossed wiping fabric has a 3.5 fold improvedwiping rate over the unembossed wiping fabric for a water film on aglass surface. With regard to usage on the diamond embossed side, theimprovement is fivefold. The wiping rate of the embossed wiping fabricis substantially improved over an unembossed wiping cloth for wiping anoil film on a glass surface. On the diamond side, the improvement issixfold; on the perforated plate side, the improvement is over ninefold.

EXAMPLE Ill A pair of cooperating mating embossing plates as illustratedin PM]. 110 is prepared to the following specifications: the longdiagonal of the diamond land is approximately seven-sixteenths inch andthe short diagonal is approximately five-six teenths inch. The area ofone diamond is 0.0683 square inch and, since there are 5.48 diamonds persquare inch, the total embossing area in 1 square inch of plate due tothe diamond lands is 0.373 square inch or an embossing area of 37.3percent of the plate surface.

With regard to the embossed area created by the grid, the embossing areais 34.5 percent.

These mating embossing plates are used to emboss an unbondedwoodpulp-filled card web sandwich comprising outer layers of lliEYBAKrearranged apertur-ed nonwoven rayon card webs each weighing grains persquare yard and a centrally located woodpulp layer weighing 350 grainsper square yard, thus making a total weight of 600 grains per squareyard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that, with regard to usage on the diamondembossed side, the embossed wiping fabric has over a fourfold improvedwiping rate over the unembossed wiping fabric for a water film on aglass surface. With regard to usage on the grid embossed side, theimprovement is over fivefold. The wiping rate of the embossed wipingfabric is substantially improved over an unembossed wiping cloth forwiping an oil film on a glass surface, fourfold for the diamond side andfivefold for the grid side.

EXAMPLE IV The procedures of example l are followed substantially as setforth therein except that the square lands on one side measure 0.1 inchX 0.1 inch and the square lands on the other side measure 0.025 inch X0.025 inch (see lFlGS. 0 and i2). There are 13.22 square lands persquare inch in each plate. One embossing plate with the large squarelands has a surface coverage of 13.2 percent and the other embossingplate with the small square lands has a surface coverage of 0.83percent.

These mating embossing plates are used to emboss an unbondedwoodpulp-filled card web sandwich comprising outer layers of KEYBAKrearranged apertured nonwoven rayon card webs each weighing 125 grainsper square yard and a centrally located woodpulp layer weighing 350grains per square yard, thus making a total weight of 600 grains persquare yard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that the embossed wiping fabric has asubstantially improved wiping rate over the unembossed wiping fabric fora water film on a glass surface. The wiping rate of the embossed wipingfabric is also substantially improved over an unembossed wiping clothfor wiping an oil film on a glass surface.

EXAMPLE V The procedures of example i are followed substantially as setforth therein except that the square lands on one side measure 0.15 inchX 0.l5 inch and the square lands on the other side measure 0.025 inch X0.025 inch (see: lFllG. 13). There are 13.22 square lands per squareinch in each plate. One embossing plate with the large square lands a.surface coverage of 29.7 percent and the other embossing plate with thesmall square lands has a surface coverage of 0.83 percent. These matingembossing plates are used to emboss an unbonded woodpulp-filled card Websandwich comprising outer layers of KEYBAK rearranged apertured nonwovenrayon card webs each weighing 125 grains per square yard and a centrallylocated woodpulp layer weighing 350 grains per square yard, thus makinga total weight of 600 grains per square yard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that the embossed wiping fabric has asubstantially improved wiping rate over the unembossed wiping fabric fora water film on a glass surface. The wiping rate of the embossed wipingfabric is also substantially improved over an unembossed wiping clothfor wiping an oil film on a glass surface.

EXAMPLE Vi The procedures of example i are followed substantially as setforth therein except that the embossing land areas on one matingembossing plate are rectangular and measure 0.2 inch X 0.15 inch and theembossing land areas on the other mating embossing plate measure 0.025inch X 0.025 inch. (See FIG. 14). There are 13.22 embossing land areasper square inch in each plate. One plate with the large rectangularlands has a surface coverage of 39.7 percent and the outer plate withthe small square lands has a surface coverage of 0.83 percent.

These mating embossing plates are used to emboss an unbondedwoodpulp-filled card web sandwich comprising outer layers of KEYBAKrearranged apertured nonwoven rayon card webs each weighing 125 grainsper square yard and a centrally located woodpulp layer weighing 350grains per square yard, thus making a total weight of 600 grains persquare yard.

Comparison of the wiping rate of such an embossed wiping fabric with anonwoven fabric which is identical in all respects thereto except thatit is not embossed reveals that the embossed wiping fabric has asubstantially improved wiping rate over the unembossed wiping fabric fora water film on a glass surface. The wiping rate of the embossed wipingfabric is also substantially improved over an unembossed wiping clothfor wiping an oil film on a glass surface.

Although the present invention has been described with reference tospecific embodiments thereof, it is to be appreciated that such has beendone for illustrative purposes and that the present invention is not tobe considered limited thereby, except as noted in the appended claims.

What is claimed is:

I. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, and a pattern ofunembossed, uncompacted fibrous portions lying between said planes andconnecting said embossed, compacted fibrous areas.

An embossed nonwoven fabric as defined in claim 1 wherein the embossedcompacted fibrous areas are in the form of polygons.

3. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are in the form of squares.

4. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are in the form of diamonds.

5. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas cover from a fraction of 1 percent toabout 90 percent of the surfaces of each side of said embossed nonwovenfabric.

6. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas over from about percent to about 40percent of the surfaces of each side of said embossed nonwoven fabric.

7. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are substantially the same on each sideof said embossed nonwoven fabric whereby the surface coverages thereofare the same.

8. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are different on each side of saidembossed nonwoven fabric whereby the surface coverages thereof aredifferent.

9. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are compacted to substantially the samedegree of compaction.

10. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are compacted to different degrees ofcompaction.

11. An embossed nonwoven fabric as defined in claim 1 wherein theintermittently spaced, embossed compacted fibrous areas lying in theplane of one surface of said web are connected to the intermittently saced embossed compacted fibrous areas lying in the plane 0 the othersurface of said web by channels of embossed compacted fibrous areas.

12. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a carded fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, and a pattern ofunembossed, uncompacted fibrous portions lying between said planes andconnecting said embossed, compacted fibrous areas.

13. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, and a pattern ofunembossed, uncompacted fibrous portions lying between said planes andslantingly and angularly connecting said embossed, compacted fibrousareas.

14. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, said planes beingsubstantially parallel but offset with respect to each other, and apattern of unembossed, uncompacted fibrous portions lying between saidsubstantially parallel but offset planes and connecting said embossed,compacted fibrous areas.

12. An embossed nonwoven fabric having a textured character andfabriclike qualities of sofiness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, said layer being so embossed that aportion of one surface thereof lies in one plane and a portion of itsother surface lies in a substantially parallel but offset plane withrespect to the first plane, a pattern of intermittently spaced, embossedcompacted fibrous areas lying in the planes of both surfaces of said webof overlapping, intersecting fibers, and a pattern of unembossed,uncompacted fibrous portions lying between said planes and connectingsaid embossed, compacted fibrous areas.

3. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are in the form of squares.
 4. Anembossed nonwoven fabric as defined in claim 1 wherein the embossedcompacted fibrous areas are in the form of diamonds.
 5. An embossednonwoven fabric as defined in claim 1 wherein the embossed compactedfibrous areas cover from a fraction of 1 percent to about 90 percent ofthe surfaces of each side of said embossed nonwoven fabric.
 6. Anembossed nonwoven fabric as defined in claim 1 wherein the embossedcompacted fibrous areas cover from about 10 percent to about 40 percentof the surfaces of each side of said embossed nonwoven fabric.
 7. Anembossed nonwoven fabric as defined in claim 1 wherein the embossedcompacted fibrous areas are substantially the same on each side of saidembossed nonwoven fabric whereby the surface coverages thereof are thesame.
 8. An embossed nonwoven fabric as defined in claim 1 wherein theembossed compacted fibrous areas are different on each side of saidembossed nonwoven fabric whereby the surface coverages thereof aredifferent.
 9. An embossed nonwoven fabric as defined in claim 1 whereinthe embossed compacted fibrous areas are compacted to substantially thesame degree of compaction.
 10. An embossed nonwoven fabric as defined inclaim 1 wherein the embossed compacted fibrous areas are compacted todifferent degrees of compaction.
 11. An embossed nonwoven fabric asdefined in claim 1 wherein the intermittently spaced, embossed compactedfibrous areas lying in the plane of one surface of said web areconnected to the intermittently spaced, embossed compacted fibrous areaslying in the plane of the other surface of said web by channels ofembossed compacted fibrous areas.
 12. An embossed nonwoven fabric havinga textured character and fabriclike qualities of softness and hand andsuitable for wiping surfaces having aqueous or oleaginous liquids ormore viscous semisolids thereon comprising a carded fibrous webcontaining at least one layer of overlapping, intersecting fibers, apattern of intermittently spaced, embossed compacted fibrous areas lyingin the planes of both surfaces of said web of overlapping, intersectingfibers, and a pattern of unembossed, uncompacted fibrous portions lyingbetween said planes and connecting said embossed, compacted fibrousareas.
 13. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, and a pattern ofUnembossed, uncompacted fibrous portions lying between said planes andslantingly and angularly connecting said embossed, compacted fibrousareas.
 14. An embossed nonwoven fabric having a textured character andfabriclike qualities of softness and hand and suitable for wipingsurfaces having aqueous or oleaginous liquids or more viscous semisolidsthereon comprising a fibrous web containing at least one layer ofoverlapping, intersecting fibers, a pattern of intermittently spaced,embossed compacted fibrous areas lying in the planes of both surfaces ofsaid web of overlapping, intersecting fibers, said planes beingsubstantially parallel but offset with respect to each other, and apattern of unembossed, uncompacted fibrous portions lying between saidsubstantially parallel but offset planes and connecting said embossed,compacted fibrous areas.
 15. An embossed nonwoven fabric having atextured character and fabriclike qualities of softness and hand andsuitable for wiping surfaces having aqueous or oleaginous liquids ormore viscous semisolids thereon comprising a fibrous web containing atleast one layer of overlapping, intersecting fibers, said layer being soembossed that a portion of one surface thereof lies in one plane and aportion of its other surface lies in a substantially parallel but offsetplane with respect to the first plane, a pattern of intermittentlyspaced, embossed compacted fibrous areas lying in the planes of bothsurfaces of said web of overlapping, intersecting fibers, and a patternof unembossed, uncompacted fibrous portions lying between said planesand connecting said embossed, compacted fibrous areas.